Cone Crusher Applications

Cone Crusher – A Sound Investment for Mining Industry: MechTech Engineers

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Cone crusher is like gyratory crusher in terms of technology but are popular in secondary, tertiary, and quaternary crushing stages. However, when sometimes the grain size of the processed material is small and the traditional primary crushing stage is not required, these crushers can carry out the first stage of the crushing process. Cone crushers have an oscillating shaft and the material is crushed in a crushing cavity, between an external fixed element (bowl liner) and an internal moving element (mantle) mounted on the oscillating shaft assembly. An eccentric shaft rotated by a gear and pinion produces the oscillating movement of the main shaft. The C eccentricity causes the cone head to oscillate between the open side setting and closed side setting discharge opening. The disintegration of material results from the continuous compression between the liners around the chamber. An additional crushing effect occurs between the compressed particles, resulting in less wear of the liners. This is also called inter particular crushing.

According to Jaimin Patel, Managing Director, Mechtech Engineers, the amount of material moving through the cone, the machine’s power drawn, the size distribution of the products coming out of the circuit, and the shape of the product are all factors to consider when using a cone crusher in a crushing circuit. The objective is to crush the feed material with the least amount of effort and economic expense for achieving the necessary results. The following parameters can affect the rate of production and the quality of the product produced by cone crushers: head diameter, the slope of the cone crushing chamber (angle), cone stroke of the head, gyrating speed, manganese liner profile/crushing chamber, the setting of closed side (CSS), applied power, and control of the feed. “The output product of any crushing operation is influenced by the physical qualities of the feed material. Properties of the material qualities that can affect the crushing process are abrasiveness, compressive strength, bulk density, friability, plasticity, feed gradation, and moisture content. The reduction ratio can measure size reduction achieved in an individual crusher application. Cone crushers in secondary crushing applications are typically equipped with the 3.5:1 to 5:1 reduction ratio. Tertiary cone crushers generally operate with a reduction ratio ranging from 2.5:1 up to 4:1,” adds Patel.

Advantages of a Long Stroke Cone-Crusher

Today’s modern, longer-stroke, high-powered machines are more efficient than those used earlier. Large stroke provides a greater area of the cross-sectional area that allows the material to go across the chamber within the specified time frame. As a result, the more time the length of the stroke, it can crush more material in a particular size machine.

Crusher Speed

The effect on crusher speed or the gyrations of the cone’s head in a minute isn’t as clear as stroke. According to the crushing stroke and the CSS and crushing chamber’s shape, the effects of increasing speed may either enhance or decrease the crusher’s productivity. In each of the above, a particular “sweet spot” in speed can result in maximum throughput for the feed. Generally, a coarse one, like secondary cones within an open circuit, should be used at the lowest part within the range.

When the crushing gets finer, increasing the speed seems advantageous, specifically when the shape of the crusher is an issue, so it is suggested to use tertiary crushers run in closed circuits and at the top limit within the speed spectrum. It is important to recognize that the faster the crusher operates, the more quickly manganese wears. The lifespan of the other mechanical components may also decrease. Thus, the optimal speed for any application is the one that produces the desired rate of production as well as the desired shape, gradation, and form.

What are the limitations of CSS?

For all cone crushers, the lowest dosed-side setting will be the one that is close to the point at which the factory’s suggested limitation of the operating pressure is reached, and this is the time where the CSS is opened through the hydraulic release mechanism. Based on the specific circumstances and the crushing characteristics of the material to be treated, the minimum CS can be larger or less than the published specifications. The plastic or clay debris in the crusher teed must be removed to prevent the formation of compacted materials called ‘pancakes,’ which are inelastic and trigger the tramp iron rebellion system. Producing quality product The rock breaking during the compression crusher could result in a proportion of the elongated or flat product. However, most construction specifications rock products need a unidirectional product. The cubit of cone crusher products is improved by the right selection of the circuit design screen and operating parameters of the crusher.

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